Instrument panel with passenger airbag

ABSTRACT

An instrument panel includes a substrate having an outer surface and an inner surface, a covering, a foam layer between the outer surface and the covering, and a chute elongated to an end. The end is attached to the inner surface. The end includes a protrusion elongated along a perimeter of the end and extending through the substrate into the foam layer.

BACKGROUND

Vehicles are equipped with airbags. In the event of an impact, aninflator activates and provides inflation medium to the airbags, and theairbags pressurize and act as cushions for occupants during the impact.The airbags are located at various fixed positions in passenger cabinsof vehicles. Vehicles typically include a driver airbag mounted in thesteering wheel, a passenger airbag mounted in the instrument panel in avehicle-forward direction from the front passenger seat, and side aircurtains mounted in the roof rails.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a top view of a passenger cabin of a vehicle.

FIG. 2 is an exploded perspective view of an instrument panel of thepassenger cabin of FIG. 1.

FIG. 3 is a cross-sectional view of the instrument panel of FIG. 2 withan airbag in an uninflated position.

FIG. 4 is a cross-sectional view of the instrument panel of FIG. 2 withthe airbag in an inflated position.

DETAILED DESCRIPTION

An instrument panel includes a substrate having an outer surface and aninner surface, a covering, a foam layer between the outer surface andthe covering, and a chute elongated to an end. The end is attached tothe inner surface, and the end includes a protrusion elongated along aperimeter of the end and extending through the substrate into the foamlayer.

The instrument panel may further include a housing including the chuteand a door, and the door may at least partially cover the end of thechute and be adjacent the substrate. The housing may include a hingeconnecting the door to the end of the chute. The protrusion and thehinge in combination may be elongated along substantially all theperimeter of the end of the chute.

The housing may be a single piece. The housing may include a flangeextending outward from the chute. The door and the flange may beattached to the substrate. The door and the flange may be welded to thesubstrate.

The hinge may have an S-shaped cross-section.

The substrate may include a slot elongated along the perimeter of theend of the chute away from the hinge. The slot may be shaped to receivethe protrusion.

The door may be attached to the substrate.

The protrusion may have a constant cross-section along the perimeter ofthe end of the chute. The cross-section of the protrusion may bewedge-shaped. The wedge-shape of the cross-section of the protrusion mayhave an angle less than 45°.

The chute may be welded to the substrate.

The instrument panel may further include an airbag disposed in thechute.

With reference to the Figures, an instrument panel 32 in a vehicle 30includes a substrate 34 having an outer surface 36 and an inner surface38, a covering 40, a foam layer 42 between the outer surface 36 and thecovering 40, and a chute 44 elongated to an end 46. The end 46 isattached to the inner surface 38. The end 46 includes a protrusion 70elongated along a perimeter of the end 46 and extending through thesubstrate 34 into the foam layer 42.

The instrument panel 32 may be a foam-in-place instrument panel, and thedesign of the instrument panel 32 allows for bottom-up installation ofthe chute 44. The chute 44 allows for a larger airbag 66, both laterallyand longitudinally, than other designs while still deploying the airbag66 sufficiently quickly and cleanly along a score line 94 of thecovering 40. The instrument panel 32 reduces foam fragmentation,provides more consistent opening of the instrument panel 32, improvesturtle necking, and allows multiple types of scoring techniques on thecovering 40 because the protrusion 70 concentrates the force of theairbag 66 inflating on the foam layer 42 and the covering 40.

With reference to FIG. 1, the vehicle 30 includes a passenger cabin 47to house occupants, if any, of the vehicle 30. The passenger cabin 47includes a driver seat 48 and a passenger seat 50 disposed at a front ofthe passenger cabin 47 and one or more back seats 52 disposed behind thedriver seat 48 and passenger seat 50. The passenger cabin 47 may alsoinclude third-row seats (not shown) at a rear of the passenger cabin 47.In FIG. 1, the driver seat 48 and passenger seat 50 are shown to bebucket seats, but the seats 48, 50, 52 may be other types. The positionand orientation of the seats 48, 50, 52 and components thereof may beadjustable by an occupant.

The instrument panel 32 may be disposed at a forward end of thepassenger cabin 47 and face toward the driver seat 48 and passenger seat50. The instrument panel 32 may include vehicle controls, such as asteering wheel; gauges, dials, and information displays; heating andventilation equipment; a radio and other electronics; etc. As describedbelow, the instrument panel 32 may be a foam-in-place instrument panel,i.e., assembled by injecting the foam layer 42 between the substrate 34and the covering 40.

With reference to FIGS. 2 and 3, the instrument panel 32 includes thesubstrate 34. The substrate 34 is elongated laterally, i.e., in avehicle-crosswise-direction, across the passenger cabin 47 and curvedalong a longitudinal direction, i.e., a vehicle-forward direction. Theouter surface 36 of the substrate 34 faces the passenger cabin 47, andthe inner surface 38 faces away from the passenger cabin 47. The outersurface 36 is a concave side of the substrate 34, and the inner surface38 is a convex side of the substrate 34. The substrate 34 may be aplastic and/or a composite, e.g., glass-filled polypropylene.

The substrate 34 includes a slot 54. The slot 54 may be U-shaped; morespecifically, a portion of the slot 54 may be elongated laterally, andtwo portions may be elongated longitudinally, i.e., in a vehicle-forwarddirection, from ends of the laterally elongated portion of the slot 54.The slot 54 may have a constant width along its length. The substrate 34may include a notch 92 elongated between ends of the slot 54. The notch92 may be a weakened area, e.g., of less thickness than surroundingareas. The notch 92 may be formed as the substrate 34 is formed byinjection molding, or the notch 92 may be formed by laser weakening aportion of the substrate 34 after formation.

The foam layer 42 is disposed between the substrate 34, e.g., the outersurface 36, and the covering 40. The foam layer 42 may be, e.g.,polyurethane in a foamlike structure, i.e., with empty cells dispersedthroughout.

The covering 40 extends over the outer surface 36 of the substrate 34and over the foam layer 42. The covering 40 may be a material that isaesthetically pleasing to occupants, e.g., leather. The covering 40 mayinclude the score line 94, i.e., a weakened area that will be opened byan airbag 66 inflating.

A housing 56 includes the chute 44, a door 58, a hinge 60 connecting thedoor 58 to the chute 44, and a flange 62. The housing 56 may beintegral, i.e., may be a single piece, i.e., may be made of a single,uniform piece of material with no seams, joints, fasteners, or adhesivesholding the housing 56 together. The housing 56 may be positioned infront of, i.e., in a vehicle-forward direction from, the passenger seat50.

The chute 44 has a tubular shape that is elongated from a bottom panel64 to the end 46. The chute 44 may have a rectangular cross-sectionalshape, e.g., with rounded corners. The bottom panel 64 may be closed,and the end 46 may be open. An inside lateral cross-sectional width ofthe chute 44 may be approximately equal to a lateral length of the slot54, and an inside longitudinal cross-sectional width of the chute 44 maybe approximately equal to a longitudinal length of the slot 54. Anoutside lateral cross-sectional width of the chute 44 may be longer thanthe lateral length of the slot 54, and an outside longitudinalcross-sectional width of the chute 44 may be longer than thelongitudinal length of the slot 54. Moreover, the chute 44 may includestiffeners 90 elongated from the bottom panel 64 to the end 46, and thestiffeners 90 extend further outside the lateral and longitudinal lengthof the slot 54. At least some of a perimeter of the end 46 of the chute44 is elongated along the slot 54. The slot 54, e.g., an entire lengthof the slot 54, is elongated along the perimeter of the end 46 of thechute 44. The slot 54 may be elongated along the perimeter of the end 46of the chute 44 away from the hinge 60.

The airbag 66 is disposed in the chute 44. The airbag 66 may be apassenger airbag. The airbag 66 may be sized to cushion an occupant ofthe passenger seat 50 during a frontal impact to the vehicle 30. Theairbag 66 is inflatable from an uninflated position, as shown in FIG. 3,to an inflated position, as shown in FIG. 4.

The flange 62 extends outward from the chute 44. Specifically, theflange 62 extends outward from the perimeter of the end 46. The flange62 faces the substrate 34 and may be shaped to conform to the substrate34.

The door 58 at least partially covers the end 46 of the chute 44. Thedoor 58 is adjacent to the substrate 34. One side of the door 58 facesthe substrate 34, and the other side of the door 58 faces the airbag 66.

The hinge 60 connects the door 58 to the end 46 of the chute 44. Thehinge 60 is elongated along some of the perimeter of the end 46 of thechute 44; e.g., the hinge 60 may be elongated along a section of theperimeter of the end 46 of the chute 44 along which the slot 54 is notelongated. The hinge 60 may be elongated along the notch 92. The hinge60 may be connected to a vehicle-forward edge of the door 58. The hinge60 has an S-shaped cross-section, i.e., a cross-section following atleast two curves turning opposite directions, i.e., a cross-sectionfollowing at least two curves with concave sides facing oppositedirections.

The door 58 and the end 46 of the chute 44 define a gap 68 therebetween.The gap 68 may be elongated along the perimeter of the end 46 of thechute 44. The gap 68 may be elongated along substantially all the slot54. The hinge 60 and the gap 68 in combination may be elongated alongsubstantially all the perimeter of the end 46 of the chute 44. The gap68 may have a substantially constant width along its length.

The housing 56 is attached to the substrate 34. For example, the flange62 and/or the door 58 are attached to the inner surface 38 of thesubstrate 34. The flange 62 and/or the door 58 may be directly attachedto the substrate 34 in any suitable manner, e.g., adhesion, fastening,welding, etc. For example, the flange 62 and/or the door 58 may befriction-welded to the inner surface 38 of the substrate 34, i.e., mayhave a boundary between the substrate 34 and the flange 62 and/orbetween the substrate 34 and the door 58 melted together so that themolecules intermingle across the boundary. The flange 62 and/or the door58 may include ribs 88 at which the friction welding has occurred. Thechute 44 may be attached, e.g., friction-welded, to the substrate 34 viathe flange 62 and/or the door 58.

The end 46 of the chute 44 includes the protrusion 70 elongated alongthe perimeter of the end 46. The protrusion 70 extends through thesubstrate 34, e.g., through the slot 54, and into the foam layer 42,i.e., at least partially through the foam layer 42. The protrusion 70 iselongated along the gap 68 and along the slot 54, and the slot 54 isshaped to receive the protrusion 70.

The protrusion 70 has a constant cross-section along its length, i.e.,along the perimeter of the end 46 of the chute 44. The cross-section ofthe protrusion 70 has a wedge shape terminating at an angle pointed intothe foam layer 42. The angle may be an acute angle; more specifically,the angle may be less than 45°. The angle helps to concentrate the forceof the airbag 66 during inflation.

With reference to FIG. 4, in the event of, e.g., an impact to thevehicle 30, the airbag 66 inflates. As the airbag 66 inflates, theairbag 66 pushes against the chute 44 and the door 58. The stiffness ofthe chute 44 concentrates the force of the airbag 66 against the door58. The S-shaped cross-section of the hinge 60 allows the hinge 60 tobend and the door 58 to rotate open relative to the chute 44. The slot54 and the protrusion 70 define a weak point for the force of the airbag66 to concentrate. The door 58 breaks through the foam layer 42 and thecovering 40, and the airbag 66 expands in front of an occupant of thepassenger seat 50. The airbag 66 cushions the occupant and may reduceinjury.

The disclosure has been described in an illustrative manner, and it isto be understood that the terminology which has been used is intended tobe in the nature of words of description rather than of limitation. Manymodifications and variations of the present disclosure are possible inlight of the above teachings, and the disclosure may be practicedotherwise than as specifically described.

What is claimed is:
 1. An instrument panel comprising: a substratehaving an outer surface and an inner surface; a covering; a foam layerbetween the outer surface and the covering; and a chute elongated to anend, the end attached to the inner surface, the end including aprotrusion elongated along a perimeter of the end and extending throughthe substrate into the foam layer; wherein the chute is welded to thesubstrate.
 2. The instrument panel of claim 1, further comprising ahousing including the chute and a door, the door at least partiallycovering the end of the chute and being adjacent the substrate.
 3. Theinstrument panel of claim 2, wherein the housing includes a hingeconnecting the door to the end of the chute.
 4. The instrument panel ofclaim 3, wherein the protrusion and the hinge in combination areelongated along substantially all the perimeter of the end of the chute.5. The instrument panel of claim 3, wherein the housing is a singlepiece.
 6. The instrument panel of claim 5, wherein the housing includesa flange extending outward from the chute.
 7. The instrument panel ofclaim 6, wherein the door and the flange are attached to the substrate.8. The instrument panel of claim 7, wherein the door and the flange arewelded to the substrate.
 9. The instrument panel of claim 3, wherein thehinge has an S-shaped cross-section.
 10. The instrument panel of claim3, wherein the substrate includes a slot elongated along the perimeterof the end of the chute away from the hinge.
 11. The instrument panel ofclaim 10, wherein the slot is shaped to receive the protrusion.
 12. Theinstrument panel of claim 2, wherein the door is attached to thesubstrate.
 13. The instrument panel of claim 1, wherein the protrusionhas a constant cross-section along the perimeter of the end of thechute.
 14. The instrument panel of claim 13, wherein the cross-sectionof the protrusion is wedge-shaped.
 15. The instrument panel of claim 14,wherein the wedge-shape of the cross-section of the protrusion has anangle less than 45°.
 16. The instrument panel of claim 1, furthercomprising an airbag disposed in the chute.
 17. An instrument panelcomprising: a substrate having an outer surface and an inner surface; acovering; a foam layer between the outer surface and the covering; achute elongated to an end, the end attached to the inner surface, theend including a protrusion elongated along a perimeter of the end andextending through the substrate into the foam layer; and a housingincluding the chute and a door, the door at least partially covering theend of the chute and being adjacent the substrate; wherein the housingincludes a hinge connecting the door to the end of the chute; and thehinge has an S-shaped cross-section.
 18. An instrument panel comprising:a substrate having an outer surface and an inner surface; a covering; afoam layer between the outer surface and the covering; a chute elongatedto an end, the end attached to the inner surface, the end including aprotrusion elongated along a perimeter of the end and extending throughthe substrate into the foam layer; and a housing including the chute anda door, the door at least partially covering the end of the chute andbeing adjacent the substrate; wherein the housing includes a hingeconnecting the door to the end of the chute; the housing is a singlepiece; the housing includes a flange extending outward from the chute;and the door and the flange are attached and welded to the substrate.